Composite material vehicle door with steel-aluminum mixed reinforced frame

Abstract

The invention relates to the field of automobile doors, in particular to a composite automobile door with a steel-aluminum mixed reinforced frame, which comprises a composite automobile door inner plate, a metal main body bearing frame assembly, a composite automobile door outer plate and an automobile door glass guide rail, and the automobile door glass guide rail is connected with an automobile door integrated die-casting aluminum frame through screws. Compared with the prior art, the light-weight automobile door has the advantages that the light-weight automobile door is better met, and the appearance modeling is light-transmitting, wave-transmitting, corrosion-resistant and the like.

Description

Technical Field

[0001] The present invention relates to the field of automobile doors, and more particularly to a composite material door with a steel-aluminum hybrid reinforced frame. Background Art

[0002] Currently, in traditional vehicle design, both the inner and outer panels of automobile doors and the inner reinforcement members are formed by stamping steel plates or aluminum alloy plates, and then connected in the form of welding + hemming to form an assembly. Although steel plates have the advantages of good toughness and high strength, they are too heavy; moreover, the parts after stamping are exposed to the air and are prone to corrosion. A large amount of cost also needs to be spent on surface treatments such as cavity wax spraying, electrocoating, and painting for the door assembly during use. Although aluminum alloy plates are light in weight and not easily corroded, they are costly and difficult to process.

[0003] With the development of society, the demand of end-users for the beauty and personalization of automobile styling is becoming more and more prominent; limited by the stamping process, the current traditional sheet metal doors can hardly meet the styling and personalization needs of customers. Secondly, with the development of automobile intelligence, more and more radars need to be arranged in the whole vehicle and doors, and millimeter-wave radars with higher sensitivity cannot penetrate steel plates and aluminum plates, so the traditional sheet metal doors can hardly meet this requirement.

[0004] Currently, existing composite material doors usually have a structure where the inner and outer panels are made of plastic and are reinforced with a steel frame or an aluminum alloy frame. However, the overall weight reduction of some composite material door assemblies is low, and the connection forms between the inner and outer panels and the frame are mostly bolted, with the bolt joints exposed, resulting in an unattractive appearance. At the same time, due to the limitations of the connection structure of the door assembly itself and the heat deformation characteristics of the plastic material itself, it is very difficult to solve the problem of door appearance matching. Chinese Patent CN219339156U discloses a composite material door system, which can meet the requirements of appearance styling, light transmission, wave transmission, etc. that cannot be achieved by traditional sheet metal doors through plasticization of the inner and outer panels. However, in order to ensure the achievement of performance, the reinforced frame structure is relatively complex, the number of parts is large, and the manufacturing process is complex. Summary of the Invention

[0005] The purpose of the present invention is to overcome the defects of the above-mentioned existing technologies and provide a composite material door with a steel-aluminum hybrid reinforced frame to solve the problems existing in the existing composite material doors, such as low weight reduction, large number of parts, complex structure, complex process of the reinforced frame, unattractive appearance at the connection of the inner and outer panels, and poor appearance matching, so as to better realize the mass production of composite material doors, better meet the requirements of automobile doors for weight reduction, appearance styling, light transmission, wave transmission, anti-corrosion, etc. that cannot be achieved by traditional sheet metal doors, and the solution and concept of the present invention are applicable to both framed doors and frameless doors.

[0006] The purpose of the present invention can be achieved by the following technical solutions:

[0007] A composite vehicle door with a steel-aluminum hybrid reinforced frame, comprising:

[0008] The composite door inner panel, metal main body load-bearing frame assembly, and composite door outer panel are connected in sequence from the inside to the outside. The metal main body load-bearing frame assembly and the composite door inner panel are connected by adhesive and bolts, and the composite door outer panel and the metal main body load-bearing frame assembly are connected by adhesive.

[0009] The metal main body load-bearing frame assembly includes: an integrated die-cast aluminum door frame, a door anti-collision beam with one end located in the middle of the integrated die-cast aluminum door frame and the other end located at the bottom of the integrated die-cast aluminum door frame, a door outer window sill reinforcement beam horizontally located on the top side of the integrated die-cast aluminum door frame, a door outer water-cut reinforcement plate connected in parallel with the door outer window sill reinforcement beam, and a door handle reinforcement plate located at the corner of the door structure and connected to the door outer window sill reinforcement beam.

[0010] The composite vehicle door further comprises a vehicle door glass guide rail, which is connected to the composite vehicle door inner panel via screws.

[0011] Furthermore, the composite door inner panel is a glass fiber door inner panel or a carbon fiber reinforced composite door inner panel.

[0012] Furthermore, the integral die-cast aluminum frame of the vehicle door is in the shape of a U.S. coin.

[0013] Furthermore, one end of the door anti-collision beam is connected to the middle position of the integral die-cast aluminum frame of the door through screws, and the other end is connected to the bottom position of the integral die-cast aluminum frame of the door.

[0014] Furthermore, the cross-section of the vehicle door outer window sill reinforcement beam is in the shape of a U, a R or a 井.

[0015] Furthermore, the outer water-cut reinforcement plate of the vehicle door is an aluminum alloy plate.

[0016] Furthermore, the outer door water-cut reinforcement plate is connected to the outer door window sill reinforcement beam by rivets.

[0017] Furthermore, the upper portion of the door handle reinforcement plate is connected to the door outer window sill reinforcement beam by rivets, and the rear portion is connected to the integral die-cast aluminum frame of the door by rivets.

[0018] Furthermore, the composite door outer panel is a polypropylene or polycarbonate panel.

[0019] Furthermore, the door glass guide rail is a fiberglass guide rail.

[0020] Furthermore, the composite material car door further includes a door module, which is connected to the inner panel of the composite material car door by snap connection or screws. For frameless car doors, the guide rails of the window regulator usually need to be adjusted to achieve a good match with the surrounding environmental components of the car door after the glass is raised. Based on this feature, the window regulator usually needs to be installed separately and assembled from the inside of the car door body, and modular assembly of the window regulator cannot be achieved, thus reducing the general assembly efficiency. This door module can pre-assemble other window regulator accessories such as the guide rails and motors of the window regulator on this door module, and then directly assemble the door module with the lifting mechanism on the outer panel of the car door body onto the composite material car door assembly; furthermore, modular installation can be achieved during general assembly, thus realizing modular assembly of the window regulator for frameless car doors.

[0021] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0022] The present invention solves the problems existing in the existing composite material car doors, such as low lightweight level, large number of parts, complex structure, complex process of the reinforcement frame, unbeautiful appearance at the connection of the inner and outer panels, and poor appearance matching. Thus, the mass production level of the composite material car door can be better achieved, and the requirements of the car door for lightweight, appearance styling, light transmission, wave transmission, anti-corrosion, etc., which cannot be met by many sheet metal car doors, can be better satisfied. And the solution and concept of the present invention are applicable to both framed car doors and frameless car doors. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 is a schematic structural diagram of a composite material car door with a steel-aluminum hybrid reinforcement frame according to the present invention;

[0024] Figure 2 is an exploded view of the structure of a composite material car door with a steel-aluminum hybrid reinforcement frame according to the present invention;

[0025] Figure 3 is a schematic structural diagram of the metal main body load-bearing frame assembly of a composite material car door with a steel-aluminum hybrid reinforcement frame according to the present invention;

[0026] Figure 4 is a schematic connection diagram of the metal main body load-bearing frame assembly and the inner panel of the composite material car door of a composite material car door with a steel-aluminum hybrid reinforcement frame according to the present invention;

[0027] Figure 5 is a schematic connection diagram of the metal main body load-bearing frame assembly and the outer panel of the composite material car door of a composite material car door with a steel-aluminum hybrid reinforcement frame according to the present invention;

[0028] Reference numerals in the drawings: composite material inner door panel 1, integrated die-cast aluminum door frame 2, door anti-collision beam 3, outer window sill reinforcement beam of the door 4, outer water cut reinforcement plate of the door 5, door handle reinforcement plate 6, composite material outer door panel 7, door glass guide rail 8, door module 9, metal main body bearing frame assembly 10, riveting point 11, rivet 12, screw joint two 12, screw 13, screw joint one 14, adhesive point 15, bonding point 16, mounting interface 17. Detailed implementation manners

[0029] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0030] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc. indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. It is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as a limitation to the present invention.

[0031] Embodiment

[0032] This embodiment provides a composite material door for a steel-aluminum hybrid reinforced frame, which solves the problems existing in the existing composite material doors, such as low lightweight level, large number of parts, complex structure, complex process of the reinforced frame, unbeautiful appearance at the joint of the inner and outer panels, and poor appearance matching. Thus, it can better realize the mass production level of the composite material door, better meet the requirements of the automobile door for lightweight, appearance modeling, light transmission, wave transmission, anti-corrosion, etc., which cannot be met by many sheet metal doors, and the solution and concept of the present invention are applicable to both framed doors and frameless doors.

[0033] The following is in accordance with Figures 1 - 3 As shown, through the description of the embodiment, the specific implementation manners of the present invention are further described in detail. It includes the description of the overall composition of the composite material door system, the explosion diagram of the system assembly, the schematic diagram of the assembly and installation structure strategy, etc.

[0034] As Figure 1 shown, it is a schematic structural diagram of the composite material door assembly of the present invention, and the structure of the present invention is shown as a whole through the transparent outer panel; the following elaborates on each detail in the present invention.

[0035] As Figure 2 shown, it is an exploded view of the structure of the composite material door assembly of the present invention, Figure 2Intuitively shows the main components of the composite material car door system except for accessories such as glass and window regulator assemblies, including: composite material inner door panel 1, metal main body bearing frame assembly 10, and composite material outer door panel 7.

[0036] In this embodiment, the metal main body bearing frame assembly 10 (as Figure 3 shown) includes: integral die-cast aluminum door frame 2, door anti-collision beam 3, outer door sill reinforcement beam 4, outer door water cut reinforcement plate 5, and door handle reinforcement plate 6;

[0037] In this embodiment, the integral die-cast aluminum door frame 2 adopts the vacuum die-casting process. Under the condition of meeting the performance requirements, the structural design can be more flexible and lighter compared with the traditional sheet metal stamping formed door structure. As Figure 3 shown, the frame structure type is a square shape. The front part of the square shape provides the installation structure for the hinge and limiter, ensuring that the installation stiffness and strength requirements of the hinge and limiter are met. The upper part provides the installation structure for the inner door water cut, ensuring that the installation stiffness requirement of the inner sill is met. The rear part provides the installation structure for the door lock, ensuring that the installation stiffness and strength requirements of the door lock are met. The lower part provides the installation structure for the window regulator, ensuring that the stiffness requirement and strength requirement of the window regulator installation point are met;

[0038] In this embodiment, the door anti-collision beam 3 adopts the hot stamping forming process of high-strength steel. As Figure 3 shown, the front end is connected to the middle position of the front part of the integral die-cast aluminum door frame 2 through screws (the direction along arrow A is from front to back), and the rear end is connected to the lower position of the rear part of the integral die-cast aluminum door frame 2 (the direction along arrow B is from top to bottom), ensuring the door collision safety requirements;

[0039] In this embodiment, the outer door sill reinforcement beam 4 is an extruded aluminum structure, and the cross-sectional form is a square shape, or a Japanese character shape, or a well character shape. As Figure 4 shown, both ends are respectively connected to the integral die-cast aluminum door frame 2 at screw connection point 14 and screw connection point 12 through screws, ensuring the outer sill stiffness requirement. For models with higher collision requirements, the performance requirements can be achieved by changing the cross-sectional size;

[0040] In this embodiment, the outer door water cut reinforcement plate 5 is formed by aluminum alloy stamping, provides the outer water cut installation structure, and is connected to the outer door sill reinforcement beam 4 through rivets;

[0041] In this embodiment, the door handle reinforcement plate 6 is an aluminum alloy stamping model, provides the outer door handle installation structure. As Figure 3 shown, the upper part is connected to the outer door sill reinforcement beam 4 through rivets, and the rear part is connected to the integral die-cast aluminum door frame 2 through rivets; ensuring that the door handle does not fail during the collision and the door does not open accidentally.

[0042] Among them, the one-piece die-cast aluminum frame 2 of the car door, the door anti-collision beam 3, the outer window sill reinforcement beam 4 of the car door, the outer water cut reinforcement plate 5 of the car door, and the door handle reinforcement plate 6 are connected together to jointly form a steel-aluminum hybrid reinforced frame, which is the performance-bearing main structure of the car door of the present invention. As Figure 4 shown, it is riveted to the composite material car door inner panel 1 through adhesive points 15 and rivets at riveting points 11, and is adhesively connected to the composite material car door outer panel 7 to ensure the realization of collision safety, stiffness, modal, and durability performance. Through such a design, the thermal deformation of the inner and outer panels of the car door at high and low temperatures can be controlled. Thus, the appearance matching of the car door is better guaranteed, and the requirements for the door gap and surface difference are ensured to be met.

[0043] In this embodiment, as Figure 2 shown, the metal main body bearing frame assembly 10 further includes a car door glass guide rail 8, which is made of glass fiber reinforced material and injection molded. As Figure 4 shown, it is connected to the above-mentioned one-piece die-cast aluminum frame 2 of the car door through screws 13. Compared with the roll-formed guide rail used in traditional sheet metal car doors, it is lighter in weight and more cost-effective.

[0044] In this embodiment, for frameless car doors, it further includes a car door module 9. As Figure 2 shown, for frameless car doors, the guide rail of the window regulator usually needs to be adjusted to achieve a good match with the surrounding environmental parts of the car door after the glass is raised. Based on this characteristic, the window regulator usually needs to be installed separately and needs to be assembled from the inside of the car door body, and modular assembly of the window regulator cannot be achieved, which reduces the total assembly efficiency. The door module of the present invention can pre-assemble the guide rail of the window regulator and other window regulator accessories such as motors on the door module, and then directly assemble the door module with the lifting mechanism on the composite material car door assembly on the outer panel of the car door body; furthermore, modular installation is achieved during total assembly, thus realizing modular assembly of the frameless car door window regulator.

[0045] In this embodiment, the composite material car door inner panel 1 is injection molded with glass fiber or carbon fiber reinforced composite material:

[0046] 1. In terms of appearance: The exposed inner panel appearance surface on one side is no longer limited to the color of the whole vehicle like a sheet metal car door or an aluminum alloy car door. The composite material car door inner panel of the present invention can be completely independent of the whole vehicle painting process, and the color and surface treatment of the exposed appearance surface on one side of the inner panel can be customized. For example, customized spraying of high-grade colors different from the body color or leather grain paint and leather grain surface treatment can be carried out;

[0047] 2. In terms of anti-corrosion: It avoids the anti-corrosion problems of the car door inner panel caused by welding or paint cracking in traditional sheet metal car doors;

[0048] 3. In terms of process: Generally, components such as speakers, wiring harnesses, domain controllers, collision sensors, and detection antennas need to be assembled inside the inner panel of the car door, and these components need to avoid the glass and the window regulator. Due to the limitations of its own process, the traditional stamping sheet metal car door cannot well cooperate with the design of the installation structure for the layout positions of the components. However, for the composite material inner panel of the car door of the present invention, the forming process is injection molding, which can maximize the cooperation with the layout positions of the components to design the installation structure, so as to better save the layout space and maximize the space for vehicle occupants;

[0049] In this embodiment, the composite material outer panel 7 of the car door is injection molded with composite materials such as PP and PC, and has the advantage of diversified styling that the traditional sheet metal stamping car door does not have, and can achieve some complex styling features, such as aerodynamic features, etc.:

[0050] 1. Light transmission advantage: The outer panel can integrate ambient lights to meet the personalized needs of users;

[0051] 2. Wave transmission advantage: Without opening holes in the outer panel, millimeter-wave radars with higher sensitivity can be arranged at various positions of the outer panel, which better realizes the intelligent requirements of the vehicle;

[0052] Such as Figure 5 As shown, the metal main body load-bearing frame assembly 10 of the present invention is connected to the composite material outer panel 7 of the car door in the form of adhesive at the bonding point 16, avoiding screw connection and achieving good sealing effect and aesthetic appearance effect.

[0053] The composite material car door with a steel-aluminum hybrid reinforced frame provided in this embodiment further includes a door module 9. For frameless car doors, the guide rails of the window regulator usually need to be adjusted to achieve a good match between the raised glass and the surrounding environmental parts of the car door. Based on this feature, the window regulator usually needs to be installed separately and assembled from the inside of the car door body, and modular assembly of the window regulator cannot be achieved, which reduces the general assembly efficiency. The door module of the present invention can pre-assemble the guide rails of the window regulator, motors and other window regulator accessories on the door module, and then directly assemble the door module with the lifting mechanism on the outer panel of the car door body onto the composite material car door assembly; thus, modular installation is achieved during general assembly, and modular assembly of the frameless car door window regulator is realized.

[0054] The assembly process of the composite material car door with a steel-aluminum hybrid reinforced frame provided in this embodiment is as follows:

[0055] First, place the composite door inner panel 1 into the tire membrane and fix it, and apply adhesive to the corresponding position of the composite door inner panel 1; then place the door integrated die-cast aluminum frame 2 into the tire membrane and bond it to the composite door inner panel 1, and then tighten the bolts at the corresponding screw connection positions; then use screws and rivets to assemble the door anti-collision beam 3, the door outer window sill reinforcement beam 4, the door outer water-cut reinforcement plate 5, the door handle reinforcement plate 6 and the door glass guide rail 8 respectively.

[0056] Then put the above subassembly into another tire membrane, apply adhesive to the corresponding position of the composite door outer panel 7, and bond the composite door outer panel 7 after coating with adhesive to the subassembly in the tire membrane to form the composite door assembly of the present invention. If it is a frameless door, the door module 9 is assembled with other accessories of the door (the surrounding environment parts belonging to the door: limiter, door lock, window lifter, glass, line speed, domain controller, pressure sensor, etc.) and then connected to the installation interface 17 (such as Figure 4 As shown) is assembled on the composite material vehicle door inner panel 1.

[0057] The above description of the embodiments is intended to facilitate understanding and use of the invention by those skilled in the art. It will be apparent that those skilled in the art can readily make various modifications to these embodiments and apply the general principles described herein to other embodiments without requiring inventive effort. Therefore, the present invention is not limited to the above-described embodiments. Improvements and modifications made by those skilled in the art based on the disclosure of the present invention, without departing from the scope of the present invention, should be within the scope of protection of the present invention.

Claims

1. A composite material car door with a steel-aluminum hybrid reinforced frame, characterized in that Comprising: A composite material door inner panel (1), a metal main body bearing frame assembly (10), and a composite material door outer panel (7) that are sequentially connected from the inside out. The metal main body bearing frame assembly (10) is connected to the composite material door inner panel (1) by adhesive and bolts, and the composite material door outer panel (1) is connected to the metal main body bearing frame assembly (10) by adhesive. Among them, the metal main body bearing frame assembly (10) includes: a door integrally die-cast aluminum frame (2), a door anti-collision beam (3) with one end located at the middle position of the door integrally die-cast aluminum frame (2) and the other end located at the bottom of the door integrally die-cast aluminum frame (2), an outer door sill reinforcement beam (4) horizontally arranged on the top side of the door integrally die-cast aluminum frame (2), an outer door water cut reinforcement plate (5) connected in parallel with the outer door sill reinforcement beam (4), and a door handle reinforcement plate (6) arranged at the corner of the door structure and connected to the outer door sill reinforcement beam (4). This composite material door further includes a door glass guide rail (8), and the door glass guide rail (8) is connected to the composite material door inner panel (1) by screws.

2. The composite material car door with a steel-aluminum hybrid reinforced frame according to claim 1, characterized in that, The composite material door inner panel (1) is a glass fiber door inner panel or a carbon fiber reinforced composite material door inner panel.

3. The composite material car door with a steel-aluminum hybrid reinforced frame according to claim 1, characterized in that, The door integrally die-cast aluminum frame (2) is in a square shape.

4. The composite material car door with a steel-aluminum hybrid reinforced frame according to claim 1, characterized in that The door anti-collision beam (3) is connected to the door integrally die-cast aluminum frame (2) by screws.

5. The composite material vehicle door with a steel-aluminum hybrid reinforced frame according to claim 1, characterized in that, The cross-sectional shape of the outer door sill reinforcement beam (4) is square, rectangular or grid-shaped.

6. The composite material car door with a steel-aluminum hybrid reinforced frame according to claim 1, wherein The outer door water cut reinforcement plate (5) is an aluminum alloy plate.

7. The composite material vehicle door with a steel-aluminum hybrid reinforced frame according to claim 1, characterized in that, The outer door water cut reinforcement plate (5) is connected to the outer door sill reinforcement beam (4) by rivets.

8. The composite material vehicle door with a steel-aluminum hybrid reinforced frame according to claim 1, characterized in that, The upper part of the door handle reinforcement plate (6) is connected to the outer door sill reinforcement beam (4) by rivets, and the rear part is connected to the door integrally die-cast aluminum frame (2) by rivets.

9. The composite material vehicle door with a steel-aluminum hybrid reinforced frame according to claim 1, characterized in that, The composite material door outer panel (7) is a polypropylene or polycarbonate plate.

10. The composite material car door with a steel-aluminum hybrid reinforced frame according to claim 1, characterized in that, The door glass guide rail (8) is a glass fiber guide rail.

11. The composite material vehicle door with a steel-aluminum hybrid reinforced frame according to claim 1, characterized in that, This composite material door further includes a door module (9), and the door module (9) is connected to the composite material door inner panel (1) by snap connection or screws.

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